Mobile Flash Butt Welding Systems for Rails Systems ... - Schlatter

schlattergroup

Mobile Flash Butt Welding Systems for Rails Systems ... - Schlatter

Mobile Flash Butt Welding Systems for Rails

Systems AMS60 and AMS100


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Fields of applications

Mobile Schlatter Rail Welding Systems

Welding machines and systems

Worldwide flash butt welding has become

increasingly popular for production

of continuous welded rails. The dedicated

Schlatter rail welding systems

are well known for their repeated high

welding quality, the excellent alignment

accuracy, for the short preparation time

and for the short welding time, which is

less than two minutes including deburring.

The durability and the long life of

the machines paired with the high productivity

and high quality contribute to

an economically attractive production.

Flash butt welding is the most reliable joining technology for track

construction and it is a proven fact that it provides the lowest failure

frequency. Schlatter o�ers two welding machines that run in di�erent

customized systems.

The mobile rail welding machines

AMS60 and AMS100 are o�ered in

di�erent configurations. For mobile

welding of continuous welded rails,

these machines are normally integrated

into an autonomously operating

rail welding system. These systems are

equipped with diesel-generator set,

hydraulic unit, cooling unit and lifting

device. Often these systems are self-

propelled, truck-based road/rail vehicles

or container systems for use on a rail

wagon on which they are moved from

one welding position to the next.

Container systems are often used semistationary

near the job site for preparation

of long welded rails.

The welding machines AMS60 and

AMS100 can also be incorporated into

pure rail vehicles or they can be used as

“stand-alone” machines for stationary

use in the factory.


AMS60 for high-quality alignment

AMS60 welding machine

The development of the AMS60 focused on the exact alignment of the

rail ends, laterally at the running edge and vertically at the running

surface. Therefore the AMS60 is most suitable where exact alignment is

essential - as it is for high-speed railway lines.

System AMS60

In the early 1990s, Schlatter developed

the first mobile rail welding machine of

this kind, with the most innovative

feature of lateral alignment at the

running edge. Lateral alignment at the

running edge is easily selectable: left-

or right-hand side. The running surface

of the rail ends is also exactly aligned

by pushing the rail head up to vertical

stops before clamping the rail ends.

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This principle of lateral and vertical

alignment has proven its worth and

thus the AMS60 is often the preferred

machine for rail welding in high-speed

lines. In numerous countries the necessary

homologation processes have been

completed successfully.


4 AMS100 welding machine

AMS100 for bigger rail profiles

In addition to the AMS60, Schlatter developed another mobile rail welder,

the AMS100. It is simpler in design, but sturdy and it provides more

force than the AMS60. Consequently its main purpose is welding of

bigger rail cross sections that are used for higher axle loads at relatively

slow running speeds.

System AMS100

A few years ago Schlatter developed the

AMS100. Its special feature is a separate

hydraulic lifting device that pushes the

rail head to vertical stops for exact vertical

alignment of the running surface.

Thanks to a parallel guiding system of

the two machine halves it aligns the

two rail ends exactly in the middle axis

of the rails. The AMS100 features a lot

more welding force than the AMS60 and

thus it allows welding of heavy rail pro-

files and even grooved rails. It is often

used for welding of freight train track

where heavy rails are used. Nevertheless

the AMS100 has also welded in

high-speed lines in various projects and

passed the respective homologation

processes successfully.


Control unit and Schlatter Weld Analyzer

Control unit

The control systems of the mobile rail welding machines comprise

the function control (PLC), the Schlatter Weld Processor (SWEP) and

the Schlatter Weld Analyzer.

Control unit and Schlatter Weld

Analyzer

The latest generation of the Schlatter

Weld Analyzer contributes considerably

to the achievement of constant

high-quality welds. During the whole

welding process the Weld Analyzer

monitors the three main parameters

force, current and travel, and displays

them on the screen during welding.

Directly after welding its analysis shows

if all parameters were within the preset

tolerances; it then stores the weld file

in the PC.

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Supra Multiflex rail welding system

Supra Multiflex container-based rail welding system

Supra Multiflex

Container systems are especially suitable

for welding in new railway lines where

a lot of new rails have to be placed

and many welds have to be carried out.

They are also often used semi-stationary

either in the depot or close to the

job site where they weld long welded

rails for a certain section of new railway

line before they are taken to another

section. Schlatter o�ers a compact 30feet

container that contains all equipment

in a space-saving manner. As an

alternative a system is available where

the equipment is incorporated into two

20-feet containers, the energy container

and the welding container.

Container systems are especially suitable for welding continuous welded

rails directly in new railway track. They are also often used semi-stationary

in the depot or near the job site for preparation of long welded

rails for a section in a new railway line.

Energy container

• Diesel-generator set

• Diesel tank with high capacity

• Energy management control

• Connection cables to the welding

container

Welding container

Welding machine AMS60 or

AMS100

• Control cabinet with the SWEP

and Schlatter Weld Analyzer

• Swiveling lifting device for lowering

and lifting of the welding machine

• Hydraulic unit

• Cooling unit


Supra Roadfl ex truck-based rail welding system

Supra Roadfl ex

Supra Roadfl ex systems are self-propelled,

they can work completely autonomously

and they are very fl exible for

moving from one job site to the next.

For the AMS60 a four axle truck chassis

is standard, for the AMS100 a three axle

truck chassis is required.

Going into track is carried out on any

level crossing that requires little space.

Shortly afterwards the system is ready

for welding at the job site.

Supra Roadfl ex rail welding system

The truck-based system is highly fl exible as it is self-propelled and can

move from one job site to the next within a short time.

Characteristics

Supra Roadfl ex systems consist of:

• Truck chassis with diesel engine

used for traveling and also for

actuating the generator set and

the hydraulic unit

• Hi-rail system

• Generator set

• Energy management control

• Diesel tank with high capacity

• Rail welding machine AMS60 or

AMS100

• Control cabinet with the SWEP

and Schlatter Weld Analyzer

• Swiveling lifting device for lowering

and lifting of the welding machine

• Central hydraulic unit

• Cooling unit

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www.schlattergroup.com

A reliable partner in plant construction

The Schlatter Group is a world leader in plant manufacturing for

resistance welding systems and weaving machines for special

applications. With long-standing expertise in industrial engineering,

innovative fl air and a reliable customer service, the Group which

is listed in Switzerland, provides production systems o� ering high

performance and quality.

Core competence

Schlatter has almost 100 years of

expertise in plant construction,

customer-oriented solutions, a worldwide

presence and more than 400

dedicated employees. The combination

of expertise in welding and systems

technology makes Schlatter a reliable

partner in plant construction.

Segment resistance welding

Schlatter has acquired unique experience

in the development and production

of reinforcing and industrial mesh

welding systems, and mobile and

stationary rail welding machines.

Weaving segment

Under the brand Jäger, the Schlatter

Group provides state-of-the-art weaving

and fi nishing machines for the paper

machine fabric industry.

Contact

Professional contacts for sales,

technical support, customer service

and administration are available worldwide

in the Group’s companies and

at selected representatives /agents of

the Schlatter Group. You can fi nd the

relevant contact data on our Internet

site www.schlattergroup.com.

Schlatter Industries AG

Brandstrasse 24

8952 Schlieren | Switzerland

T +41 44 732 71 11

F +41 44 732 45 50

www.schlattergroup.com

2.157EN BC

Schlatter Industries AG

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